SINGLE PACKAGE ROOFTOP
STANDARD-EFFICIENCY HEAT PUMP UNITS
Cancels: NewII 548F-36-1
548F
Sizes 036-072
3-6 Tons
8/15/00
IMPORTANT — READ BEFORE INSTALLING
1. Read and become familiar with these installation
instructions before installing this unit.
2. Be sure the installation conforms to all applicable
local and national codes.
3. These instructions contai n importa nt inform ation for
the proper maintenance and repair of this equipment.
Retain these instructions for future u se.
Installation and servicing of air-conditioning equipment can
be hazardous due to system pressure and electrical components. Only trained and qualified service personnel should
install, rep air, or servic e air-conditionin g equipment.
Untrained personnel can perform basic maintenance functions of cleaning coils and filters and replacing filters. All
other operations sh o uld be perfor me d by trai ne d se rvi ce personnel. When working on air-conditioning equipment,
observe precautions in the literature, tags and labels
attached to the unit, and other safety precaution s that may
apply.
Follow all safety codes. Wear safety glasse s and work g love s.
Use quenching cloth for unbrazing operations. Have fire
extinguisher available for all brazing operations.
CAUTION: Ensure voltage listed on unit data
plate agrees with electrical supply provided for the
unit.
INSTALLATION
Unit is shipped in the vertical discharge configuration. To
convert to horizontal config uration, remove hor izontal duct
opening covers. Using the same screws, install covers on duct
openings in basepan of unit with the insulation-side down.
Seals around duct openings must be tight.
I. STEP 1 — PROVIDE UNIT SUPPORT
A. Roof Curb
Assemble and install access ory roof curb in accorda nce with
instructions shipped with curb. See Fig. 1. Install insulation,
cant strips, roofing felt, and counte r flashing as sho wn. Duct-work must be attached to curb, not to the unit. If electric or
control power is to be routed through the basepan, attach the
accessory thru-the-bottom service connections to the
basepan and roof curb in accordance with the accessory
installation instructions. Connections must be installed
before unit is set on roof curb.
IMPORTANT: The gasketing of the unit to the roof curb is
critical for watertightness. Install gasket supplied with the
roof curb as shown in Fig. 1. Improperly applied gask et can
also result in air leaks and poor unit performance.
Curb should be level. This is necessar y for unit drain to function properly. Unit leveling tolerances are shown in Fig. 2.
Refer to Accessory Roof Curb Installation Instructions for
additional information as required.
B. Slab Mount (Horizontal Units Only)
Provide a level concrete slab that exte nds a m ini mum o f 6 i n .
beyond unit cabinet. Install a gravel apron in front of condenser coil air inlet to prevent grass and foliage from
obstructing airflow.
NOTE: Horizontal units may be installed on a roof curb if
required.
II. STEP 2 — FIELD FABRICATE DUCTWORK
Secure all ducts to ro of curb and b uil ding stru cture on v ertical discharge units. Do not connect ductwork to unit. For hor-
izontal applications, field-supplied flanges should be
attached to horizontal discharge open ings and all ductwork
should be attached to the flanges. Insulate and weatherproof
all external ductwork, joints, and roof openi ngs wi th co unter
flashing and mastic in accordance with applicable codes.
Ducts passing through a n unco nditi one d spa ce mu st be ins ulated and covered with a vapor barrier.
7. Direction of airflow.
NOTES:
1. Roof curb accessory is shipped disassembled.
UNIT SIZE
A
8. Connector packages CRBTMPWR001A00 and 002A00 are for thru-the-
2. Insulated panels.
548F
curb connections. Packages CRBTMPWR003A00 and 004A00 are for
thru-the-bottom connections.
Fig. 1 — Roof Curb
PKG. ACCY.
CONNECTOR
CRBTMPWR001A00
CRBTMPWR003A00
″
″
2
2
/
/
1
“G”
CONTROL
3. Dimensions in [ ] are in millimeters.
4. Roof curb, galvanized steel.
5. Attach ductwork to curb (flanges of duct rest on curb).
6. Service clearance: 4 ft on each side.
“F”
POWER
036-072
“E”
GAS
″
″
-2
-0
′
′
1
2
[356]
[610]
HOLE
D ALT
DRAIN
1
[12.7]
[12.7]
[31.7]CRBTMPWR002A00
[31.7]CRBTMPWR004A00
″
″
4
4
[19] NPT
/
[19] NPT)
″
1
4
/
3
″
4
/
3
/
″
1
4
/
1
1
3
″
″
2
4
/
/
1
3
[19] NPT
[19] NPT
[12.7] NPT
″
4
/
3
1
[44.5]
END OF CURB AS POSSIBLE.
PLACE UNIT AS CLOSE TO THIS
ROOF CURB
″
-4
′
1
[406]
″
16
ACCESSORY
CRRFCURB001A00
CRRFCURB002A00
BC
/
11
[551]
-9
′
1
—2—
MAXIMUM ALLOWABLE
DRAIN PLUG
DIFFERENCE (in.)
A-BB-CA-C
0.51.01.0
Fig. 2 — Unit Leveling Tolerances
If a plenum return is used on a vertical unit, the return
should be ducted through th e roof deck to comply with applicable fire codes.
A minimum clearanc e to comb ustible s is no t required around
ductwork on vertical discharge units. On horizontal discharge units with electric heat, a minimum clearance of
1.0 in. is required for the first 12 in. of ductwork. Cabinet
return-air static pressure should not exceed –0.35 in. wg
with Durablade econ omizer, –0.30 in. wg with EconoMi$er,
or –0.45 in. wg without economizer.
III. STEP 3 — INSTALL CONDENSATE DRAIN LINE AND
EXTERNAL TRAP
Condensate drain connections are located on the botto m and
side of the unit. Unit discharge connections do not determine
the use of drain connections; either drain connection can be
used with vertical or horizontal discharge units.
When using the standard side drain connection, make sure
the plug in the alternate bottom connection is tight before
installing the unit.
To use the bottom drain connection for a roof curb installation, relocate the factory-installed plug from the bottom connection to the side connection. See Fig. 3. The piping for the
condensate drain and external trap can be completed after
the unit is in place.
All units must have an external trap for condensate drainage. Install a trap at least 4 in. deep and protect against
freeze-up. If drain line is installed downstream from the
external trap, pitch the line away from the 548F unit at 1 in.
per 10 ft of run. Do not use a pipe size smaller than the unit
connection.
IV. STEP 4 — RIG AND PLACE UNIT
Inspect unit for transportation damage, and file any claim
with transportation agency. Keep unit upright and do not
drop. Spreader bars are not required if top crating is left on
unit, and rollers may be used to move unit across a roof.
Level by using unit frame as a reference. See Table 1 and
Fig. 4 for additional information. Operating weight is shown
in Table 1 and Fig. 4.
Lifting holes are provided in base rails as shown in Fig. 4
and 5. Refer to rigging instructions on unit.
CAUTION:
A. Positioning
Maintain clearance around and above unit to provide proper
airflow and service access. See Fig. 5.
A properly positioned unit will have the following clearances:
1
/4-in. clearance between roof curb and base rails on each
side and front of unit;
rear of unit. (See Fig. 1, section C-C.)
Do not install unit in an indoor location. Do not locate unit
air inlets near exhaust vents or other sources of contaminated air.
Although unit is weatherproof, guard against water from
higher level runoff and overhangs.
After unit is in position, remove polyethylene shipping wrapper and top crating.
NOTE:
Drain plug is shown in factory-installed position.
Fig. 3 — Condensate Drain Connection (Side View)
1
/4-in. cleara nc e b et w ee n r o of c u rb a nd
—3—
NOTES:
1. Dimension in ( ) is in millimeters.
2. Hook rigging shackles through holes in base rail, as shown in
detail ‘‘A.’’ Holes in base rails are centered around the unit center
of gravity. Use wooden top skid when rigging to prevent rigging
straps from damaging unit.
3. Unit weights do not include economizer. See Table 1 for economizer weights.
All units except 208/230-v units are factory wired for the
voltage shown on the nameplate. If the 208/230-v unit is to
be connecte d to a 208-v p ower sup ply, the tr ansfor mer must
be rewired by dis connecting the black wire fr om the 230-v
1
/4-in. male spade terminal on the transformer and connecting it to the 208-v
transformer.
Refer to unit label diagram for additional information. Pigtails
are provided for field wire connections. Use factory-supplied
1
/4-in. male spade terminal from the
splices or UL (Underwriters’ Laboratories) approved copper/
aluminum connector .
When installing units, provide a disconnect per the NEC. All
field wiring must comply with the NEC and local
requirements.
Install field wiring as follows:
1. Install conduit through side panel ope nings . For units
without electric heat, install conduit between disconnect and control box.
2. Install power lines to terminal connections as shown
in Fig. 6.
3. For units with electric heat, refer to Accessory Electric Heat Installation Instructions.
During operation, voltage to compressor terminals must be
within range in dicate d on unit n amepla te (a lso se e Tables 2A
and 2B). On 3-ph as e uni ts, vo lta ge s be tw e en ph as es mu st be
balanced within 2% and the current within 10%. Use the formula shown in Tables 2A and 2B, Note 2, on page 12 to
determine the percentage of voltage imbalance. Operation on
improper line v oltage or excessive phas e imbalance constitutes abuse and may cause damage to electrical components.
Such operation invalidates any applicable Bryant warranty.
NOTE: If accessory thru-the-bottom connections and roof
curbs are used, refer to the thru-the-bottom accessory installation instructions for information on wiring the unit.
—4—
Table 1 — Physical Data
UNIT SIZE 548F036048060072
NOMINAL CAPACITY (tons)
OPERATING WEIGHT (lb)
Unit
Al/Al*
Al/Cu*
Economizer
Durablade
EconoMi$er
Roof Curb†
COMPRESSOR
Quantity
Oil (oz)
REFRIGERANT TYPE
Operating Charge (lb-oz)
OUTDOOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
OUTDOOR FAN
Nominal Cfm
Quantity...Diameter (in.)
Motor Hp...Rpm
Watts Input (Total)
INDOOR COIL
Rows...Fins/in.
Total Face Area (sq ft)
INDOOR FAN
Quantity...Size (in.)Std
Type DriveStd
Nominal Cfm
Maximum Continuous BhpStd
Motor Frame SizeStd
Nominal Rpm High/LowStd
Fan Rpm RangeStd
Motor Bearing Type
Maximum Allowable Rpm
Motor Pulley Pitch Diameter Min/Max (in.)Std
Nominal Motor Shaft Diameter (in.)Std
Fan Pulley Pitch Diameter (in.)Std
Belt, Quantity...Type...Length (in.)Std
Pulley Center Line Distance (in.)Std
Speed Change per Full Turn of
Movable Pulley Flange (rpm)Std
Movable Pulley Maximum Full Turns
From Closed PositionStd
Factory SettingStd
Factory Speed Setting (rpm)Std
Fan Shaft Diameter at Pulley (in.)
HIGH-PRESSURE SWITCH (psig)
Standard Compressor Internal Relief (Differential)
Cutout
Reset (Auto.)
*Heater capacity (kW) is based on heater voltage of 208 v, 240 v, or 480 v. If
power distribution voltage to unit varies from rated heater voltage, heater kW
will vary accordingly.
†Used to determine minimum disconnect per NEC.
**Heaters are field installed only.
††Fuse or HACR circuit breaker.
Electrical disconnect cannot be used if electric heater is installed. (Applies to
||
any line with an FLA greater than or equal to 80.)
NOTES:
1. In compliance with NEC requirements for multimotor and combination load
equipment (refer to NEC Articles 430 and 440), the overcurrent protective
device for the unit shall be fuse or HACR breaker.
2. Unbalanced 3-Phase Supply Voltage
Never operate a motor where a phase imbalance in supply voltage is greater
than 2%.
imbalance.
LEGEND
Full Load Amps
Heating, Air Conditioning and Refrigeration
Indoor-Fan Motor
Locked Rotor Amps
Minimum Circuit Amps
Maximum Overcurrent Protection
National Electrical Code
Outdoor-Fan Motor
Rated Load Amps
Use the following formula to determine the percentage of voltage
% Voltage Imbalance
= 100 x
Example: Supply voltage is 460-3-60.
Determine maximum deviation from average voltage.
(AB) 457 – 452 = 5 v
(BC) 464 – 457 = 7 v
(AC) 457 – 455 = 2 v
Maximum deviation is 7 v.
Determine percent of voltage imbalance.
% Voltage Imbalance = 100 x
This amount of phase imbalance is satisfactory as it is below the maximum
allowable 2%.
IMPORTANT:
tact your local electric utility company immediately.
max voltage deviation from average voltage
AB = 452 v
BC = 464 v
AC = 455 v
If the supply voltage phase imbalance is more than 2%, con-
average voltage
Average Voltage =
= 457
7
457
= 1.53%
452 + 464 + 455
1371
=
3
3
—12—
B. Field Control Wiring
Install a Bryant-approved accessory thermostat assembly
according to installation instructions included with the
accessory. Locate thermostat asse mbly on a solid wall in the
conditioned space to sense average temperature in accordance with thermostat installation instructions.
NOTE: If using Bryant electronic thermostat, set thermostat
configuration f or “non-hea t pump opera tion.” The use of the
O terminal is not required to energize the reversing valve in
this family of products.
Route thermostat cable or equivalent single leads of colored
wire from subb ase term inals to low-voltage conne ctions on
unit (shown in Fig. 7) as described in Steps 1 through 3
below.
NOTE: For wire runs up to 50 ft, use no. 18 AWG (American
Wire Gage) insulated wire (35 C minimum). For 50 to 75 ft,
use no. 16 AWG insulated wire (35 C minimum). For over
75 ft, use no. 14 AWG insulated wire (35 C minimum). All
wire larger than no. 18 AWG cannot be dire ctly c onn ected to
the thermostat and will require a junction box and splice at
the thermostat.
Fig. 8 — Field Control Wiring Raceway
†
AHA —
CC—
LEGEND
Adjustable Heat Anticipator
Cooling Compensator
Field Wiring
Factory Wiring
*Used with economizer.
†Used with 2-stage electric
heater.
Fig. 7 — Low-Voltage Connections With or
Without Economizer or Two-Position Damper
1. Connect thermostat wires to screw terminals of low
voltage connection board.
2. Pass the control wires through th e hole provided in
the corner post.
3. Feed wire through the raceway built into the corner
post to the 24-v barrier located on the l eft side of the
control box. See Fig. 8. The raceway provides the ULrequired clearance between the high- and low-voltage
wiring.
C. Defrost Board
The defrost board timer is set for a 30 minute defrost cycle
from the factor y. T o a djust to a 50 or 90 minute cycle , remove
the wire connected to the 30 minute quick connect on the
defrost board. See Fig . 9. Connect lead to t he 50 or 90 minut e
quick connect on the defrost board, depending on the application.
D. Heat Anticipator Settings
Set first-stage heat anticipator setting at 0.8 and set secondstage heat anticipator settin g at 0.3.
Fig. 9 — Defrost Board
VI. STEP 6 — ADJUST FACTORY-INSTALLED OPTIONS
A. Disconnect Switch
The optional disconnect switch is non-fused. The switch has
the capability of being locked in place for safety purposes.
The disconnect switch is only available for limited applications. See electrical data tables on pages 8-12 for disconnect
switch usage.
B. Optional Durablade Economizer
The optional economizer hood assembly is packaged and
shipped in the filter section. Damper blades and control
boards are installed at the factory and the economizer is
shipped in the vertical discharge position.
NOTE: Horizontal discharge block-off plate is shipped with
the air hood package. If unit is to be used for vertical discharge application, discard this plate.
—13—
Assembly
1. Determine if ventilation air is required in building. If
so, determine the minimum amount to be supplied by
each unit and record quantity of ventilation air
needed for use in Step 7.
2. Remove filter access panel by raising panel and
swinging panel outward. Panel is now disengaged
from track an d can be removed. No tools are required
to remove filter access panel. Remove outdoor-air
opening panel. Save panels and screws. See Fig. 10.
Remove optional outd oor-air ho od pa cka ge from fil te r
section.
3. Assemble outdoor-air hood top and side plates as
shown in Fig. 11. Install seal strips on hoop top and
sides. Put aside screen retainer and retainer screw
for later assembly. Do not attach hood to unit at this
time.
4. Economizer comes factory-installed in unit and
secured with screws. See Fig. 12.
NOTE: Be sure rear economizer flange is engaged under tabs
in vertical return-air opening. See Fig. 24.
Fig. 10 — Typical Access Panel Locations
Fig. 11 — Outdoor-Air Hood Details
U-SHAPED
HOLE
(NOT
SHOWN)
ECONOMIZER
CONTROL
BOARD
ECONOMIZER
PLUG
WIRING
HARNESS
BAROMETRIC
RELIEF DAMPER
SHIPPING
SCREW
ECONOMIZER
MOTOR
POSITION SETTING
BRACKET
TOP
SCREW
Fig. 12 — Durablade Economizer Installed in Unit
5. To convert to horizontal discharge application:
a. Rotate the eco nomizer 90 degrees u ntil the econ o-
mizer motor faces the outdoor section (see Fig. 13).
b. Remove shipping screw and tape and then rotate
the barometric relief damper hinge 90 degrees.
Barometric relief damper should open vertically to
operate properly.
c. Install horizontal discharge block-off plate over the
opening on the access panel. (Block-off plate MUST
be installed before installing hood assembly.)
6. Remove existing 12-pin blue and yellow wire jumper
plug and store. Insert 12-pin economizer plug into
economizer harness. See Fig. 12.
7. If ventilation ai r is not req uired , proce ed to Step 8. If
ventilation air is required, determine the minimum
position setting for required airflow. See Fig. 14.
Adjust minimum position setting by adjusting the
screws on the position setting bracket. Slide bracket
until the top screw is in the position determined b y
Fig. 14. Tighten screws. See Fig. 15.
8. Remove tape from outdoo r-air thermost a t ( OAT). F a sten OAT to inside of hood using screws and speed
clips provided. See Fig. 16. Make sure OAT terminals
are positioned up.
9. Replace outdoor-air open ing panel usin g screws from
Step 2. Replac e filter access panel. Ensure t he filter
access panel slides along the tracks and is securely
engaged.
10. Fasten hood top and side plate assembly (Fig. 11) to
outdoor-air opening panel wit h s crews provided.
11. Place knob supplied with economizer on OAT. See
Fig. 16. Set for 3° F below indoor room thermostat
setting. If accessory enthalpy control (EC) i s used in
place of OAT, see instructions shipped with EC for
installation and adjustment . See F ig. 16.
12. Connect OAT per Fig. 17.
13. Slide outdoor-air inlet screen into screen track on
hood side plate. While holding screen in place, fasten
screen retainer to hood usi ng screws provided.
NOTE: Refer to Fig. 18 for economizer barometric relief
damper characteristics.
—14—
SHIPPING
UNIT
TOP
OAT
(TERMINALS ARE UP)
OUTSIDE AIR
SCREEN
MINIMUM
POSITION
OPEN
3
1
T
P
P1
T1
4
2
5
S
S
O
D
C
TR
B
RE
V
.B
1
9
88
1
8
A
%
H
U
M
I
D
I
T
Y
90
70
60
30
10
D
C
B
A
60
65
70
75
55
50
85
80
DAMPER
DAMPER
CLOSED
OPEN
OUTDOOR TEMP
.
°
F
R
E
V
.
9
7
-367
2
CW
–SETPOINTS
–CCW
CONT
A
CTS SHO
WN IN HIGH ENTHALPY
R
U
S
H
A
T
2
4
V
A
C
3 m
A
M
IN
. A
T 1
1 VDC
CONT
ACT RA
TINGS: 1.5A
RUN, 3.5A IN
OR UNPO
WERED ST
A
TE
1
2
3
TR
TR1
24
V
A
C
ENTHALPY CONTROL
ENTHALPY
CONTROL
HOOD
SCREW
Fig. 13 — Horizontal Discharge Durablade
Economizer Installation
Example: Given — Negative Pressure . . . . . . . . . . .0.2 in. wg